Ray dalley predict turbine ferrography 12 2006

 The harder dirt particle imbeds itself in a softer metal and gouges the metal away from the rotating metal separated by the lubricant film.. Metal Component Imbedded Particle Gouged Me

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Predict

Presentation toPiedmont Chapter Vibe InstituteFerrography Analysis on

Turbine Bearings

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Lab Service Products

 New & used lubricant & grease testing

 Hydraulic fluid testing

 Fuels testing

 Transformer oil testing

 Coolant testing

 Wear particle analysis (Ferrography)

 Supplies (pumps, oil taps, tubing, etc.)

 Training

 Program management

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Lab Analysis Reporting Equipment & Lube Condition

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Three Body Abrasive Wear

 Due to foreign particles in the oil.

 The harder dirt particle imbeds itself in a softer metal and gouges the metal away from the

rotating metal separated by the lubricant film.

Metal Component

Imbedded Particle

Gouged Metal

Lubricant Film

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Three Body Abrasive Wear

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Two Body Abrasive Wear

 Due to a misalignment or an asperity of a harder metal component gouging the opposite rotating softer metal.

Misaligned

component

Gouged Metal

Lubricant Film

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Two Body Abrasive Wear

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Air Compressor

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Gear Box

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Power Plant

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Turbine

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Bearing

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Bearing

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Small Bearings

The Basics of

Ferrographic Analysis

1 TRENDING Wear Particle Concentrations to Identify Onset of Abnormal Wear

2 PARTICLE IDENTIFICATION Microscopic & Analytical Analysis to Determine Origin & Severity

3 INTERPRETATION Analysis of All Data &

Recommendations

Wear Particle Analysis

A Three Step Process

Density Reading Ferrograph

Quantitative Analysis

 DR Ferrograph

DR General Acceptance Limits

WEAR PARTICLE CONCEN ACCEPTANCE LIMITS

Wear Particle Analysis Instruments

Qualitative Analysis

 FM Ferrograph

Wear Particle Analysis Testing

Ferrogram Maker

Distance in mm EXIT END

-5mm | +5mm Ferrous Particles

S Magnet Pole

N Magnet Pole Flux Lines w/Debris

Non-Magnetic Barrier, 2.5mm ENTRY POINT

Wear Particle Analysis Instruments

Qualitative Analysis

 Ferroscope V

Wear Particle Analysis System & Software

 Passport System V

Particle Classifications

 NON-FERROUS - COPPER ALLOYS, ALUMINUM,

BABBITTED METALS, ZINC, CHROME, ETC.

 FERROUS - MAGNETIC, PARAMAGNETIC; Fe, Fe2O3, Fe3O4; STAINLESS

 CONTAMINANT - FLUIDS; DUST, DIRT, EXTERNAL

PROCESS; MANUFACTURING DEBRIS; FILTER MATERIAL;

FRICTION POLYMERS; ORGANIC MATTER

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Normal Rubbing Wear Particles

Cutting Wear

 Indicative of Misalignment or Presence of Abrasive Contaminants

 Long, Curly Strips of Material

 Aspect Ratios Ranging From 5:1 to 50:1 (Length to Width)

 Never Considered Normal

Cutting Wear Particles

Low Alloy Steel Copper Alloy

High Alloy Steel

Bearing Wear

 Rolling Fatigue Wear

 Flat Platelets With Perforated Surfaces and Irregular Edges

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Bearing Wear Particles

Severe Sliding Wear

 Excessive Speeds/Loads on Critical Contacts Within the Equipment

 Typically Rectangular Particles With Striations Parallel to the Direction of Elongation

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Severe Sliding Wear Particles

Gear Wear

 Combined Rolling and Sliding Wear

 Flat Platelets

 Fatigue Spall - Similar to Bearing Wear Debris

 Adhesive Wear - May have striations or other surface features

 Scuffing and Scoring - Similar to Severe Sliding Wear Debris

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Gear Wear Particles

Corrosive Wear

 Due to Acidic Attack on the Internal Surfaces of Equipment

 Small Particles <1 Micron in Size

 Align Themselves on the Outer Edges of a

Ferrogram

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Corrosive Wear

Black Oxides

 Due to High Temperatures at Critical Contacts Within a Unit

 Black Particles

 Align in the Ferrous Strings

 Indicative of Boundary Lubrication Condition

Black Oxides

 Spherical Particles

 Usually 5-10 Microns in Size

 Indicative of Bearing Fatigue Prior

to a Spalling Condition

 Black Circles with Shiny Centers

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Spheres

Sand/Dirt Particles

 Contaminants Introduced Through Breather

Elements, Seals, Cylinder Heads, Etc

 Transparent, Translucent, or Opaque Crystalline

or Birefringent Material

 Deposits Over the Length of the Slide

 Easily Seen Under Polarized Light

Sand and Dirt

UNDER POLARIZED LIGHT

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Sand/Dirt Under Polarized Light

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De Laval Steam Turbine

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Turbine

Journal

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Turbine

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Courtesy of AISE

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Bearings Good/Bad

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Courtesy of AISE

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Turbine Bearings

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Courtesy of AISE

Heat Treatment Procedures

 All slides should be heat treated

if large or marginal particles are detected

 Monitor temperature of hot plate

to ensure temperature of 330oC, + or - 10oC

 Maintain slide on hot plate for at least 90 seconds to ensure

saturation of oxide layer growth

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Low Alloy Steel

 Inclusion ofsmall amounts

of alloys

 Blue Color

Inclusions on the surface

Less area for ion

formation

•Less oxide growth

Cast Iron / Medium Alloy Steel @ 330C

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Journal Bearings

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Turbine Bearings

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Journal Bearings

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Bearings

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Spalled Bearing

What Are The Benefits?

 Reduced Maintenance Costs

 Reduced Unscheduled Downtime

 Improved OEM Warranty Programs

 Adds Proactive Maintenance/Root Cause Analysis Capability

 Product Quality Improvements

 Improved Plant Safety

World Class Predictive

Maintenance Solutions

That Work for YOU!!!!